Ford Mustang (1999-2004) Service Manual: Differential Housing Cover

Removal

1. Raise and support the vehicle.

2. NOTE: Empty the lubricant into a clean container for reuse.

Remove the differential housing cover (4033).

1. Remove the 10 bolts and drain the lubricant from the differential housing (4010).

2. Remove the differential housing cover.

Differential Housing Cover

Installation

1. CAUTION: Make sure the machined surfaces on both the differential housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. To prevent contamination, cover the inside of the rear axle (4001) prior to cleaning the machined surface.

Clean the differential housing and the differential housing cover gasket mating surfaces.

2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant.

Apply a continuous bead of sealant of the specified thickness to the differential housing cover.

  • Use Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford specifications ESB-M4G92-A.

Differential Housing Cover

3. NOTE: If possible, allow one hour before filling the axle with lubricant to make sure the silicone sealant has cured.

Install the differential housing cover.

1. Install the differential housing cover.

2. Install the 10 bolts.

Differential Housing Cover

4. NOTE: In-vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to 6.4-14.3-mm (1/4-9/16-in) below the bottom of the fill hole.

Fill the rear axle to the level shown, approximately 1.54-1.66-liters (3.25-3.50-pints) of lubricant, and install the filler plug.

  • Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

Differential Housing Cover

5. Lower the vehicle.

    Installation
    1. Inspect the pinion flange seal journal for rust, nicks, and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary. 2. Lubricate the pinion flange ...

    Axle Housing Bushing
    Special Tool(s) Axle Suspension Bushing Set 204-S030 (T78P-5638-A) Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and sys ...

    Other materials:

    Installation
    1. Make sure the anti-rattle spring is correctly positioned in the caliper. 2. CAUTION: Make sure guide pin boots are correctly seated or damage to guide pins can occur. Install the disc brake caliper. 1. Hold the guide pins stationary. 2. Inst ...

    Installation
    1. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this ...

    Transmission Support Crossmember
    Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section. 2. Support the transmission with a suitable transmission jack. 3. Remove the crossmember. 1. Disconnect the HO2S sensors and position them aside. 2. ...